Apparatus and method for making flexible shafting



c. F. HOTCHKISS, JR I 2,347,631

April 25,1944.

APPARATUS AND METHOD FOR MAKING FLEXIBLE SHAFTING Filed Jan. 18,1943 5 Sheets-Sheet 1 I'll aim

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C. F. HOTCHKISS, JR

' April 25, 1944.

. APPARATUS AND METHOD FOR-MAKING FLEXIBLE SHAFTING 5 Sheets-Sheet 2 Filed Jan. 18, 1943 c. F. HOTCHKISSJR 2,347,631 1 APPARATUS AND METHOD FOR MAKING FLEXIBLE SHAFTING April 25, 1944.

Filed Jan. 18, 1943 5 Sheets-Sheet 3 Cfffiatclfass ii:

Elma Mugs C. F. HOTCHKISS, JR

APPARATUS AND METHOD FOR MAKING FLEXIBLE SHAFTING April 25, 1944.

5 Sheets-Sheet 4 Filed Jan. 18, 1943 arr/bunk, .r;

April 25, 1944- c. F. HOTCHKISS, 41R- 2,347,631

APPARATUS AND METHOD FOR MAKING FLEXIBLE SHAFTING Filed Jan. 18, 1945 5 Sheeis-Sheet 5 Patented Apr. 25; 1944 H 2,345,631 APPARATUS AND 'Ms'rnon son a ram snsr'rmc Clarence F. Hotchkiss, Jr., Binghamton, N. Y., assignor to Stow Manufacturing Company, Inc., Binghamton, N. Y., a corporation of New York Application January18, 1943, Serial No. 472,770

Claims. (Cl. 5711) This invention relates to an apparatus and method of manufacturing flexible shaiting of the with one or more successive layers or convolutions of a plurality of wires with the successive layers or wire coats layered up on the core usually composed oi. a plurality of proper gauge wires and successive layers are usually wound in opposite directions.

An object of the invention is the construction of an apparatus whereby exceedingly long lengths of flexible shaiting may be wound up in a semicontinuous manner. That is, the present machine is capable of forming lengths of shafting several hundred feet long and instead of requiring a long building similar to a rope walk the apparatus is considerably compacted whereby a length of shafting twice as long as the building may be wound.

A further object of the present apparatus is the formation of flexible shaiting starting with a central core and winding a layer of wire thereon, together with the placing of successive layers over the first wound layer. In operation, the core or previously wound shaft is fed from a reel joined intermediately of two normally equal lengths of shaiting in such a manner that only the intermediate section passes through the winding apparatus. That is, as the core or initiallywound shafting is fed from a storage reel it is in three or, more lengths joined by swivel connections so that the portion of the shafting being wound may be rotated on its longitudinal axis whereby succeeding layers are applied to the rotating section.

still further object of the present apparatus "e novelconstruction of a winding tool and iii-coat of wire thereto and simultaneously ad- --vane the wound shafting therethrough.

ing is-permitted to *lineally move while receiving axial rotation. In addition, the swivel connection between the sections of the shafting and the winding tool, or layering device are of novel construcs tion; l a l Inthe drawings:

Figure 1 is a diagrammatic layout of the entire semi-automatic flexible shaft winding machine for carrying out the features of this invention;

" I iacentlypositioned winding head whereby the central core or initially wound cable is rotated jfon its axis to smoothly and tightly apply a layer Figure 2 is a side elevation partly in crosssection of the winding head and shafting advancins app a s; t

Figure 3 is a top plan view of the winding head;

Figure 4 is a vertical cross-section taken on line t-fi of Figure 3 looking in the direction of the arrows;

Figure 5 is also a sectional view taken on line 5-5 of Figure 3 in the direction of the arrows;

Figure 6 is a vertical plan view of one of the pulleys over which the rotating shafting passes;

Figure '7 is a'vertical section of the pulley taken on line l-'l of Figure 6;

Figure 8 is a side elevation partly in crosssection of the winding or layering tool per se,' illustrating the manner of laying up a layer of wire on the initially wound shafting;

Figure 9 is a vertical section taken on line 9-9 of Figure 8 in the direction of the arrows;

Figure 10 is a similar vertical section taken on line Ill-I0 of Figure 8;

Figure 11 is a side plan view of oneof the swivel connections positioned between sections of the shafting; and i Figure 12 is a vertical section through one of the swivels showing the manner of attaching the ends of the shafting sections therein and the pivotal and rotatable mountings thereof.

It is believed that a general statement and explanation of the apparatus shown in Figure 1 will be of assistance in understanding the advantages and operation of the apparatus as a whole before describing the machine and its associated parts in detail.

Referring to Figure 1, the apparatus comprises generally a rotatable storage reel I carrying a core or previously wound shafting 3 and connected thereto by a swivel 5 is a further length of the core or initially wound shafting I. This section I extends over pulleys 9 and l I with intermediate supporting rollers l3 and, thence, around pulleys l5 and IT. The periphery of the roller I! is at such a height that the core or wire passing thereover and to be wound is fed directly through a winding tool generally denoted by the numeral It. A plurality of wires 2| carried on a supply stand 23 are fed into the Winding tool :9 where they are wound upon the initial shafting 1 as it is drawn through the tool. Axial rotation is given to this entire section of core i andiwound section I15 through the medium of a winding head 25. wThe head 25 imparts rotary movement to the sections 1 and H5 of the shafting and simultaneously pulls or feeds the wound shafting therethrough, the linear movement: of

the unwound and wound portionsof the shafting being indicated by the direction arrows. The previously wound length 21 attached to the wound portion I15 of section I passes over pulleys or drums 29, 3| and 33 to a storage reel 35 positively driven bymotor 31 and it will be obvious that the swivel 33 between these sections prevents the axial rotative movement between the section of the shafting being wound and the previously wound portion 21 thereof passing to the storage reel.

In the prior art, flexible shafts have usually been wound by stringing up a core and manually carrying along the core a perforated die plate through which wires are fed to lay on the successive convolute layers. Attempts have been made to eliminate these manual operations and to create automatic or semi-automatic machines of the present invention these prior attempts had not solved the practical difficulties involved particularly those encountered in forming larger diameter flexible shafting. As before stated, this apparatus permits a length of central core wire or a shaft which has been initially wound to be drawn and twisted during its passage through the machine, whereby a continuous, smooth, tight helix is wound upon the core or initial shaft in such a manner that a shaft of several hundred feet in length can be operated upon before readjusting the machine to carry out a further winding step.

The initial core or previously wound shaft 1 is separated from the remaining material on the reel I by a swivel 5, so that the entire length of the core or initial shafting I to be operated on turns on its longitudinal axis without imparting rotation to the portion 3. Swivel 39 prevents rotation between wound portion 21 and wound portion I I of section I. As shown in Figures 11 and 12, the swivels joining the sections of shafting throughout the apparatus comprise two pivoted members 50 and 5| journaled through the medium of a central pivoted pin 52. The member 50 is in the form of a tapered plug having a central longitudinal bore 53 therethrough for the reception of the end of the shafting or core 3 which is retained in the bore by means of a set screw 54. The plug 50 is provided with side arms 55 between which the skirt of the closed end cylinder 5| is retained by means of the pivot pin 52. Cylinder 5| has a central aperture 55 therein of smaller diameter than the normal inside diameter of the skirt or cylindrical portion thereof for retaining a ball bearing 56 therein. The meansfor securing the section of shafting I whereby relative rotary movement is permitted between the portions 3 and I comprises a sleeve 51 and a set screw 58. The sleeve 51 passes through aperture .55 and abuts the outer side wall of the press fitted ball bearing 56 and is retained thereagainst by an enlarged headed plug 59 abutting the opposite side wall of the bearing and retained in position within the end of the sleeve by set screw 60. It will be obvious that if rotative movement is given the shafting I it will not be transmitted to the portion 3 of the shafting as the swivel permits free rotation between the sections by means of the bearing 56. g

To insure that the rotative movement imparted to the portion I of the shafting being wound is transmitted throughout its entire length the pulleys 9, II, I5 and I1 are constructed in such a manner that the lineally moving and rotating shafting is properly supported while allowing for carrying out these steps but until the advent free rotation thereof. This action is accomplished by constructing these pulleys as shown in Figures 6 and 7. The pulleys are preferably constructed of two spaced parallel disks I5 and I6 joined by a suitable number of horizontal brackets 11 made up of parallel bars I8 and I3 between which are mounted a pair of spaced freely rotating rollers 80. The side bars I8 and I9 are cut away at their central upper portions adjacent the peripheries of the rollers whereby the shafting, in passing over the pulleys or drum, will not bind against the side bars. Pulleys constructed in this manner permit the free longitudinal movement of the shafting 'I therearound and, as the shafting is only supported on the adjacent peripheries of the rollers 80, the rotation imparted to the shafting is freely permitted and, consequently, the waiting will not bind against the pulleys as it is drawn through the winding tool I9. The winding head 25 and winding tool or d l9 are mounted intermediate the lower pulleys I5 and IT on a fixed base and are contiguous to each other.- The winding head 25 through which the section I and wound portion H5 is drawn and rotated is positively driven by a jack shaft l0| suitably connected by belts or other powertransmitting means to a motor I00. The jack. shaft is supported in antifriction bearings I02 mounted in the supporting frame I I3. The winding head accomplishes two purposes, namely, the rotation of the shafting whereby the wires 2| feeding through winding tool l9 are layered up or wound upon the core or initially wound shaft and, secondly, the drawing through or imparting linear movement to the shaftlng as the winding progresses. The winding head per se is shown in detail in Figures 2 to 5, inclusive, and consists of an open box-like frame composed of a pair of channel irons I03 affixed to end plates I04 and I05. The other pair of channels Ill and I53, I54, as will be hereinafter described.

The end plates I04 and I05 of the box frame are rotatably supported o tubular shafts I20 and I35, respectively. The right-hand hollow axle I20, as shown in Figure 3, is supported within the inner race I06 of a ball bearing having its outer race I08 fitted in a journal IIO amxed in the upper part of frame I I3. This end assembly is held in adjusted position by a nut 200 threaded on the tubular shaft I20 inside the cover plate 20I.

The left-hand hollow axle |35, the larger diameter portion 204 of which is pressed into a depression in the end plate I05, is supported within the inner race I01, of a ball bearing haw'ng its outer race I09 fitted in a ioumal III affixed to the upper part of frame II3. This end assembly is held in adjusted position by a nut 205 threaded on thetubular shaft I35.

The tubular shaft I3| is mounted for independent rotatio in spaced bearings 202 and 203. The inner bearing 202 is supported in the larger diameter portion 204 of sleeve I35. The bearing 203 holding the outer end of the sleeve I3I is fitted with an annular-opening of flanged cover cylinder 200 and retained in position by nut 20! and cover 200 prime. The bearing 203 holding the outer end of the sleeve I3| is fitted within an annular opening of flanged cover cylinder and retained in position by nut 201 and cover A drive pulley I2I is secured on the outer end of the hollow shaft I20 whereby rotative movement is given the entire box frame I03 when the drive pulley I2I thereon is connected to the jack shaft II. An intermediat belt tightener I22 may be interposed between the jack shaft pulley I86 and frame drive shaft pulley I2 I.

A similar drive pulley I30. is secured on thetubular shaft I3I. The inner end of tubular shaft I3I terminates in a gear I32, so that, when movement is imparted tothe driven pulley I30 and hollow shaft "I3I it freely turns through the end plate and has no effect upon the rotative movement thereof. The end gear I32 meshes with an offset pinion I33 carried on a bolt I34 extending through the end plate I and carries thereon a second pinion I36 of smaller diameter also carried on the bolt I34. This reduced diameter pinion I36 meshes with pinion I31 which is of larger diameter and is secured to a hori zontal shaft I38 extending from the end plate I05 to a bearing I39 carried on the arm I40 extending between the ends of two of the shorter channels I03. A similar vertical arm MI is mounted on the opposite sides of the upper and lower shorter channels I03 in spaced relation to the arm I40 and, between these arms, an axial bolt I42 is mounted carrying a beveled wheel I43. An upwardly extending yoke or fork I50 is also positioned on the axial bolt I42 and carries between its upper sides a non-metallic wheel I5I. The end of the yoke I50 is pivotally secured to an adjustable turnbuckle rod I52, having a screwthreaded end passing through an arm I53 which bridges the opposite pair of the shorter box frame members I03. Secured to the opposite side of the corresponding frame members is a second arm I54 and between these arms is positioned an axle I55 on which is mounted a grooved pulley wheel I56.

The horizontal shaft I38 driven by gear I31 is provided with a worm I58 that meshes with Worm gear I59 carried on the shaft I80 journaled between the frame members I03 extending from end plate I04 to end plate I05. A larger diameter pulle'y IIiI is mounted on shaft I80 and positively driven by the worm and gear I58, I59.

In operation, the core or the initially wound cable is threaded through the driven tubular axle I3I and passes over a portion of thegrooved freely rotating pulley I56 and in contact with the periphery of the driven wheel IBI and thence over free pulley I43 and outwardly from the winding head through driven axle I20. The shafting is preferably wound around the driven pulley I8! a plurality of turns to insure sufiicient frictional contact therewith for continuously and smoothly drawing the shafting through the winding head. This contact is additionally secured by maintaining the periphery of the upper free wheel I5! against .the flexible shafting on the driven pulley by means of the pivoted yoke I and its adjustable turnbuckle I52. The convolutions of the shafting on the driven pulley are maintained in parallel relation and prevented from overrunning each other by means of a pivoted knife or finger I85 in contact with the shafting as it is started on the pulley I6I through the tension exerted by coil spring I08.

Asbefore stated, the drive pulleys I2! and I30 are rotated from lower parallel jack shaft I 0|.

The power to pulley i 2| for rotating the cage or frame of the winding head is taken oil from pulley I88 and through suitable belting or the like over belt tightener I22 to the upper pulley. The drive pulley I30 through which the gear chain previously desscribed rotates the shafting advancing drum IGI is similarly driven from the jack shaft through an adjustable speed pulley I01 and belt tightener I88. Normally the drive pulley I30 is driven at a somewhat faster rate of rotation than is the drive pulley I2 I Just prior to 'the advancing of the shaftin through the winding head the initially wound ehafting 1 passes through the wire laying device I9 where the plurality of strands of wire composing the helix or coat I15 are laid up thereon. The wound shafting I15 is advanced and rotated as it passes through the winding head 25 and, as before described, the swivels 5 and 39 permit only the initially wound portion 1 and the additionally wound portidn I15 of the shafting to rotate.

Figures 8, 9 and 10 disclose the draw plate or wire laying tool construction. Essentially, it consists of an exteriorly threaded adjustable bushing I mounted in a holder I8I and maintained in any fixed desired position by set screw I82. A hardened end thimble I83 is inserted in the end of the bushing where the incoming wire strands contact the end of the bushing as they are laid on the shafting 1. The holder I 8| .is provided with an enlarged base portion I84, having a pair I of spaced parallel and horizontal bores I85 therethro'ugh, and is. carried on a pair of parallel rods I86 secured in. end plates I81 and I88. Coil springs I89 and I90 are carried on the rods I 38 between the end of the base portion I 84 and the end plate I88 and also between the oppositeend of the base plate and stop collars I9I. This permits adjustment of the position of the winding tool and the coil springs I89 and I90, and this arrangement will take up any shock or jar to which the shafting being wound may be subjected. The end of the base portion I84 opposite the outer end of the bushing I80 carries an upwardly extending partition I having a screw threaded opening therein for the retention of a wire guiding and draw plate I92. This plate has a central opening I93 in axial alinement with the bore of the bushing I80 and a plurality of wire receivin openings I94 radially and circumferentlally arranged about the central opening. Wires 2I from the supply spools 23 mounted on a swivelable carrier are fed through the openings I94 andto the bushing I 83 where they are guided and wound upon the moving shafting 1. It will be observed that the opening I93 of the plate I92 and the bore of bushing I 80 are in axial alinement and register with the opening in hollow driven shaft I3I of the winding head 25. The layer being wound up on the initial shafting 1 is indicated. by numeral I15.

This novel method of forming large diameter flexible shafting and apparatus for carrying out the method allows exceptionally long lengths of shafting to be manufactured in a semi-automatic manner and within a cgmparatively small space.

What I claim is:

l. The method of winding a plurality of closely adjacent wire helices on to a length of core comprising swivelably connecting said length of core between a second length of core and a previously wound length of core, leading said first length of core through a tool wherein a series of continuous wire strands are wrapped around the periphery thereof, and simultaneously advancing the length of core to be wound, thelength of unwound core and the previously wound length length of ly with the winding of the first length of core be.

ing rotated.

3. An apparatus for forming flexible shafting comprising in combination a plurality of lengths of core swivelably joined to each other, means for advancing all of said core lengths, and means for,

drawing and rotating one of said core lengths through a wire winding tool wherein a plurality of wire strands are directed onto the periphery of the said rotating and advancing core length.

4. In a flexible shafting forming machine, the

combination therewith of a plurality of lengths of flexible shafting core swivelably connected together, one of the lengths of flexible shafting adapted to be rotated relative to the adjoining lengths of connected flexible shai'ting, the swivelable connections :between said lengths comprisin oppositely extending hinged sections, a socket in one of said sections for retaining the end of one of the lengths of flexible shafting, the other of said sections having an anti-friction bearing supported therein and a flexible shafting and connection retained within said anti-friction bearing whereby said flexible shafting end connection may freely turn within said bearing.

5. A flexible shafting forming machine and swivelable connection therefor as defined in claim 4 wherein one of the said pivoted sections is cylindrical and provided with a restricted aperture at its outer end,-a ball bearing mounted in the cylinder adjacent the said restricted aperture, an enlarged headed stud passing through theopening in inner race ring of the said ball bearing outwardly through the said restricted aperture and a hollow sleeve secured to the outer end of said stud; the outer portion of said hollow sleeve adapted to hold the end of a length of flexible shafting therein.

' CLARENCE F.. HOTCHKISS, JR. 

